Part 1
Axle
Front Axle Assembly - Disassembled View
Disassembly
1. Remove the axle assembly. For additional information, refer to Axle Assembly Axle Assembly.
2. Remove the 10 bolts and the differential housing cover.
- Drain the fluid.
- Remove the bolts.
- Remove the differential housing cover.
3. NOTICE: The fixture mounting bolts must have the minimum specified thread engagement in the carrier or damage to the component may occur.
Install the Transmission Holding Fixture.
4. Using the Transmission Fluid Pump Remover and Slide Hammer, remove the intermediate shaft.
5. Remove the 4 bolts and the axle housing tube.
6. NOTICE: The housing spreader adapter bolts must have the minimum specified thread engagement in the carrier or damage to the component may occur.
Install the Differential Housing Spreader Plate and Adapter for Differential Housing Spreader.
7. Position the Differential Carrier Spreader on the spreader adapters.
8. Install the Dial Indicator Gauge with Holding Fixture and Clutch Holding Gauge.
- Position the adapter tip in the spreader adapter hole.
9. NOTICE: Overspreading may damage the axle housing.
Spread the axle housing to the specification.
1. Adjust the Dial Indicator Gauge to zero.
2. Tighten the housing spreader screw to spread the axle housing to the specification.
3. Remove the Dial Indicator Gauge with Holding Fixture.
10. NOTE: Mark the differential bearing caps Top or Bottom and LH or RH appropriately before removing them. Always install the bearing caps in their original place and position.
Mark and remove the 2 differential bearing caps.
1. Remove the bolts.
2. Remove the differential bearing caps.
11. NOTICE: Use wood blocks to avoid axle housing damage.
Remove the differential assembly from the axle housing.
1. Position the wood blocks.
2. Position and push down on the 2 pry bars.
3. Remove the differential assembly.
4. Remove the Differential Carrier Spreader.
12. Index-mark the axle U-joint flange to the pinion stem.
13. Install the Drive Pinion Flange Holding Fixture and loosen, but do not remove, the pinion nut.
14. With the pinion nut still engaged by a few threads, use the 2 Jaw Puller to separate the axle U-joint flange from the pinion gear.
15. Remove the nut and the flange.
16. Using the Drive Pinion Thread Protector and a soft hammer, remove the pinion gear.
17. Discard the drive pinion collapsible spacer.
18. NOTICE: Do not damage the carrier housing while removing the pinion seal.
Remove the pinion seal and slinger.
- Pry up on the seal flange. Install gripping pliers, and strike with a hammer to remove the seal.
19. Remove the outer pinion bearing.
20. Using the Bearing Cup Remover and Slide Hammer, remove the inner pinion bearing cup.
21. NOTE: The pinion bearing oil baffle aids in bearing lubrication. Normally, it is not necessary to remove the baffle.
If necessary, remove the pinion bearing oil baffle.
22. Remove the outer pinion bearing cup by tapping alternately on each side to prevent the cup from cocking.
23. Using the Bearing Remover and a suitable press, remove the pinion bearing.
24. NOTE: A drive pinion bearing adjustment shim sits under the pinion bearing. Use a micrometer to measure the shim thickness. Record the measurement for comparison to the shim gauge reading taken prior to installing the pinion bearing.
Remove and measure the drive pinion bearing adjustment shim.
25. NOTE: Use a drift punch to separate the ring gear from the differential case.
Remove and discard the 10 bolts and remove the ring gear.
26. Using the 2 Jaw Puller and Step Plate, remove the differential bearings.
Assembly
1. NOTICE: Do not omit the pinion bearing oil baffle; bearing failure may result.
If removed, position the baffle on the Drive Carrier Bearings Installer.
2. Using the Drive Carrier Bearings Installer, install the baffle.
3. NOTE: Always install new pinion bearings when installing new pinion bearing cups.
Lightly oil the new pinion bearing cups and pinion bearings with front axle lubricant.
4. Using the Drive Pinion Bearing Cup Installer, install the bearing cups.
5. NOTE: The pinion bearings assembled in this procedure step must be used at final assembly.
Assemble and position the Adapters and the pinion bearings in the carrier housing.
1. Position the screw adapter.
2. Position the aligning adapter.
3. Position the pinion bearing.
4. Position the gauge disc adapter.
5. Position the gauge block adapter.
6. Position the pinion bearing.
7. Thread on the handle adapter.
6. NOTE: This step duplicates final pinion bearing preload.
Tighten the Adapter to simulate bearing preload.
- Tighten to 2.2 Nm (20 lb-in).
7. NOTE: Offset the gauge block adapter to obtain an accurate reading.
Rotate the gauge block Adapter several half-turns to make sure the pinion bearings seat correctly and position the gauge block adapter.
8. Install the Drive Pinion Gauge Tube.
1. Position the Drive Pinion Gauge Tube.
2. Install the 2 differential bearing caps.
3. Install the 4 bolts.
- Tighten to 105 Nm (77 lb-ft).
9. NOTE: Use only flat, clean drive pinion bearing adjustment shims.
NOTE: Do not attempt to force the shim between the gauge block adapter and the gauge tube adapter. A slight drag indicates correct shim selection.
Use a drive pinion bearing adjustment shim as a gauge for shim selection.
- Check the adjustment shim thickness between the gauge block adapter and the gauge tube adapter.
- After determining the correct shim thickness, remove the Drive Pinion Gauge Tube.
10. NOTE: The same pinion bearings from the previous steps must be used.
Install the pinion bearing.
- Place the drive pinion bearing adjustment shim on the pinion gear.
- Using a suitable press and the Drive Pinion Bearing Cone Installer, press the pinion bearing until it is firmly seated on the pinion gear.
11. Place a new drive pinion collapsible spacer on the pinion stem.
12. Install the outer pinion bearing.
13. Install the slinger.
14. NOTE: Coat the lips of the pinion seal with front axle lubricant.
Place the pinion seal on the Drive Pinion Oil Seal Installer.
15. Place the Drive Pinion Oil Seal Installer and seal in the pinion seal bore and drive the seal into place.
16. Lightly lubricate the pinion gear splines with front axle lubricant.
17. Position the drive pinion in the housing.
18. NOTICE: Never install the drive pinion U-joint flange with a hammer or power tools.
NOTE: Disregard the scribe marks if installing a new flange.
Align the index marks and position the U-joint flange on the drive pinion.
19. Using the Drive Pinion Flange Installer, install the drive pinion U-joint flange.
20. Apply a small amount of lubricant to the washer side of the new pinion nut, and install the nut.
21. NOTICE: Do not loosen the pinion nut to reduce preload under any circumstance. If it is necessary to reduce preload, install a new drive pinion collapsible spacer and pinion nut or damage to the component may occur.
Install the Drive Pinion Flange Holding Fixture and tighten the pinion nut. Refer to the torque specifications in the Specifications.
- Rotate the pinion gear occasionally to make sure the pinion bearings are seating correctly. Take frequent pinion bearing torque preload readings by rotating the pinion gear with a Nm (lb-in) torque wrench.
22. Use a fine flat file to remove any burrs or nicks from the ring gear mounting surface.
23. Install the differential ring gear.
1. Place the differential ring gear on the differential assembly.
2. Hand-start 3 ring gear bolts to align the holes in the differential ring gear and the differential assembly.
3. Place the differential carrier and differential ring gear onto the press bed blocks with the differential gear teeth facing downward.
4. Press the differential ring gear into place.
24. Install the remaining new bolts.
- Tighten to 128 Nm (95 lb-ft).
25. NOTE: Press against the bearing inner core only.
Using a suitable press and the Differential Side Bearing Installer, install the differential bearings.
1. Position the appropriate differential bearing (RH or LH).
2. Using a suitable press and the Differential Side Bearing Installer, install the differential bearing.
- Repeat the procedure for the other differential bearing.
